UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Autonomous Maintenance Programme for

Drilling Machine

Report submitted in accordance with the requirements of the Universiti Teknikal

Malaysia Melaka for the Bachelor’s Degree in Manufacturing Engineering

(Manufacturing Management)

By

Hafiziana Binti Othman

Faculty of Manufacturing Engineering

April 2008

oval

UTeM Library (Pind.1/2005)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)

BORANG PENGESAHAN STATUS TESIS*

JUDUL: AUTONOMOUS MAINTENANCE PROGRAMME FOR DRILLING MACHINE

SESI PENGAJIAN: 2007/2008

Saya HAFIZIANA BINTI OTHMAN

mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran

antara institusi pengajian tinggi.

4. **Sila tandakan (√)

SULIT

TERHAD

√

√

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam

AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS)

Alamat Tetap: NO.246, KAMPUNG LINTANG, PETRA JAYA, 93050, KUCHING, SARAWAK. DATE: 29 APRIL 2008

Disahkan oleh:

(TANDATANGAN PENYELIA)

Cop Rasmi: Tarikh: _______________________

* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

iii

DECLARATION

I hereby, declared this report entitled “Autonomous Maintenance Programme for Drilling

Machine” is the results of my own research except as cited in references.

Signature : ………………………………………….

Author’s Name : Hafiziana Binti Othman

Date : …………………………………………

iv

APPROVAL

This PSM submitted to the senate of UTeM and has been as partial fulfillment of the

requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing

Management). The member of the supervisory committee is as follow:

……………… ………………

(Mr.Wan Hasrulnizzam Bin Wan Mahmood)

(Official Stamp & Date)

v

ABSTRACT

This project is performed as a preliminary study on 16/20 mm drill press machine towards

Autonomous Maintenance. This project covers Fuguai or abnormalities investigation and

the remedy for continuous improvement. For analysis, the Fuguai have been divided into

three main categories which are physical, safety and function. The results on seven weeks

of observation show that Fuguai for physical is the most critical, followed by safety and

function. Almost all of Fuguai have been eliminated; however, there are several Fuguai

that can not be eliminated because of higher technical knowledge required, new part

replacement and others.

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ABSTRAK

Projek ini dikendalikan sebagai kajian asas penyelengaraan sendiri (AM) ke atas mesin

gerudi (16/20 mm). Projek ini merangkumi penyiasatan Fuguai dan cara-cara untuk

mengatasi masalah secara berterusan. Fuguai telah dibahagikan kepada tiga kategori

utama; iaitu fizikal, keselamatan dan fungsi sebagai analisis. Kajian selama tujuh minggu

menunjukkan bahawa Fuguai fizikal adalah yang paling kritikal, diikuti keselamatan dan

fungsi. Hampir kesemua Fuguai telah diselesaikan. Walau bagaimanapun, terdapat

beberapa Fuguai yang tidak dapat dieselesaikan kerana memerlukan pengetahuan teknikal

yang tinggi, penggantian komponen baru dan sebagainya.

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DEDICATIONS

For my beloved family especially to my parents:

Mr. Othman Bin Mohd.Noor and Mrs. Dayang Ling Bt.Awang Bujang

For my supervisor:

Mr. Wan Hasrulnizzam B. Wan Mahmood

For my friends in UTeM:

Especially for the BMFU students

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ACKNOWLEDGEMENTS

In the name of Allah S.W.T, the creator of all creations, all praises to Him, the Most

Merciful and the Most Blessing, Alhamdulillah I had completed this project successfully.

First of all, I would like to thank my beloved parents, Mr. Othman Bin Mohd. Noor and

Mrs. Dayang Ling Bt.Awang Bujang for their full support and to always there for me in

giving ideas.

I would as well like to thank all UTeM lecturers and staffs especially to my PSM

Supervisor, Mr. Wan Hasrulnizzam Bin Wan Mahmood for his enthusiastic support and

great supervision and bunch of thanks to my second examiner too, Mr.Khairul Anwar Bin

Rahman.

I am gratefully acknowledging UTeM students for sharing their knowledge and for their

constructive critics and suggestions. Without all of you, I possibly will not achieve what I

have today.

Thank you again.

Hafiziana Binti Othman

ix

TABLE OF CONTENTS

Declaration……………………………………………………..……………………...….. iii

Approval……………………………………………………………………..……………..iv

Abstract…………………………………………………………………..………….……...v

Abstrak…………………………………………………………………………..……..…..vi

Dedications………………………………………………………………………..…….....vii

Acknowledgements…………………………………………………………….…...…….viii

Table of Contents…………………………………………………………..…….……..…xii

List of Figures ……………………………………………………………………...……. xv

List of Tables………………………………………………………………...….….......…xvi

List of Abbreviations, Symbols, Specialized Nomenclature……………………...…….xviii

1. INTRODUCTION………………………………………………………………..……..1

1.1 Background……………………………………………………………………………1

1.2 Problem Statement……………………………………………………………..……...2

1.3 Objectives………………………………………………………………………..…....2

1.4 Scope of Project …………………………………………………………………..…..2

1.5 Importance of Project……………………………………………………………..…..3

1.6 Report Outline……………………………………………………………………..….3

2. MAINTENANCE…………………………………………………………………...…...4

2.1 Maintenance…………………………………………………………………………...4

2.2 Importance of Maintenance………………………………………………… ...……...5

2.3 Types of Maintenance…………………………………………………………………7

2.3.1 Breakdown Maintenance………………………………………………………….7

2.3.2 Preventive Maintenance (PM)…………………………………………………….8

2.3.3.1 Periodic Maintenance (Time Based Maintenance – TBM)………………....9

2.3.3.2 Predictive Maintenance (PdM)……………………………………………...9

2.3.3 Corrective Maintenance………………………………………………………….10

2.3.4 TPM …………………………………………………………………………......10

2.3.5 Total Quality Management (TQM)……………………………………………....11

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2.3.6 Reliability-Centered Maintenance (RCM)…………………………………........12

2.3.7 Condition Monitoring (CM)…………………………………………………......12

2.4 Introduction to TPM………………………………………………………………....13

2.4.1 TPM Development……………………………………………………………....17

2.4.2 TPM Pillars……………………………………………………………………...19

2.4.2.1 Pillar 1 – 5S………………………………………………………....…......20

2.4.2.2 Pillar 2 - AM or Jishu Hozen (JH)………………………………………...22

2.4.2.3 Pillar 3 - Kobetsu Kaizen……………………………………………… ...22

2.4.2.4 Pillar 4 - Planned Maintenance…………………………………………….23

2.4.2.5 Pillar 5 - Quality Maintenance…………………………………………......24

2.4.2.6 Pillar 6 - Training and Education…………………………………………..24

2.4.2.7 Pillar 7 - Office TPM………………………………………………………25

2.4.2.8 Pillar 8 - Safety, Health and Environment…………………………………26

2.4.3 AM……………………………………………………………………………….27

2.4.3.1 Step 1- Initial Cleanup…………………………………………………….29

2.4.3.2 Step 2 - Counter Measures…………………………………………………

2.4.3.3 Step 3- Fix tentative AM Standards………………………………………..30

2.4.3.4 Step 4- General Inspection…………………………………………………30

2.4.3.5 Step 5- Autonomous Inspection……………………………………………30

2.4.3.6 Step 6- Standardization…………………………………………………….31

2.4.3.7 Step 7- Autonomous Management………………………………………...31

2.4.4 Fuguai……………………………………………………………………………32

2.4.4.1 Fuguai-tags………………………………………………………………..32

2.4.5 Overall Equipment Efficiency (OEE)……………………………………………33

3. DRILLING MACHINE (16/20 MM DRILL PRESS)……………………………….36

3.1 Introduction to Drilling Machine…………………………………………………..36

3.1.1 Development of Drilling Machine……………………………………………….36

3.1.2 Types of Drilling Machine……………………………………………………….37

3.1.3 General recommendations for Speeds and Feeds in Drilling……………………40

3.1.4 General Recommendations for Drill Geometry for High-Speed Twist Drills…..40

3.1.5 Proper Anxious Of Drilling Machines…………………………………………..41

3.2 Drill Press (16/20 mm)………………………………………………………………42

30

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3.3 Typical Drill Press Operation………………………………………………………..54

3.4 Standard of Procedures for Drill Press (16/20 mm)…………………………………56

4.METHODOLOGY ……………………………………………………………..60

4.1 Planning of the Project…………………………………………………………….…60

4.2 Data Collection…………………………………………………… ………………...64

4.2.1 Primary Data……………………………………………………… …………….64

4.2.1.1 Observation………………………………………………… ……………..64

4.2.1.2 Fuguai Investigation………………………………………… …………....64

4.2.1.3 Focused Group Discussion………………………………… ……………..65

4.2.2 Secondary Data…………………………………………………… …… ………65

4.2.2.1 Books……………………………………………………… …… ………..65

4.2.2.2 Internet Basis……………………………………………… …… ………..65

4.2.2.3 Machines Manual…………………………………………… …………...66

4.2.3 Analytical Technique…………………………………………… … …………..66

4.2.3.1 Bar Chart……………………………………………………… ….………66

4.2.3.2 Column Chart……………………………………………… … ….………66

4.2.3.3 Pareto Chart…………………………………………………… …………67

4.2.3.4 Trend Chart……………………………………………………… ……….6

4.2.3.5 Pie Chart………………………………………………………… ……….67

4.2.3.6 Spider Chart……………………………………………………… ………68

4.2.4 Fuguai Tags…………………………………………………………… … ……68

5. ANALYSIS AND DISCUSSIONS………………………………………….……....…71

5.1 Fuguai Analysis…………………………………………………………….……...71

5.1.1 Machine Area ………………………………………………….……………....72

5.1.2 Fuguai Types…………………………………………...……………………...74

5.1.3 Cleaning Check Sheet………………………………………………….………77

5.2 Analysis and Discussions…………………………………...…………….……….77

5.2.1 Analysis of Fuguai Types..……………………………………...……….……77

5.2.2 Analysis of Machine Area…………………………………………….….……81

5.2.3 Analysis of Fuguai Category……………………………………….……….…85

5.2.4 Why-Why Analysis and Countermeasure for the Fuguai…………………..…86

xii

6.0 CONCLUSION AND RECOMMENDATIONS…………………………….……...99

6.1 Conclusion……………………………………………………………………........99

6.2 Recommendations………………………………………………………….……..100

6.2.1 Current Study…………………………………………………………………100

6.2.2 Future Study…………………………………………………………….…….101

5. REFERENCES……………………………………………………………………….102

APPENDICES

A - Check Sheet

xiii

LIST OF FIGURES

2.1 Importance of Maintenance 6

2.2 Development of TPM 18

2.3 Maintenance and Production Areas in an Organization 19

2.4 TPM Pillars 19

2.5 5S diagram 21

2.6 Steps to AM 29

3.1 Example of Hammer Drill 38

3.2 Example of Rotary Hammer Drill 38

3.3 Example of Cordless Drill 38

3.4 Example of Drill Press 39

3.5 Example of Radial Arm Drill 39

3.6 Example of Mill Drill 39

3.7 Drill Press (16/20 mm) 43

3.8 Technical Drawing for a Drill Press (16/20 mm) 44

3.9 Counter Bores 55

3.10 Counter Sink 55

3.11 Center Drilling 55

3.12 Tapers Holes 55

3.13 Spot Face 55

3.14 Threaded Holes 55

3.15 Flow Chart of Drilling Operation 57

3.16 Clamping process 58

3.17 Fixing the Drill Bit 58

3.18 Drill Point Confirmation Process 58

3.19 Turn on the Switch 58

3.20 Pushing the Feed Handle Downward 59

3.21 Pushing the feed handle upward 59

3.22 Removing the Drill Bit 59

3.23 Remove the Workpiece and Clean the Machine 59

xiv

4.1 Flow Chart of the Project 62

4.2 Orange Tag 69

4.3 Green Tag 69

5.1 Machine Area 73

5.2 Rust 74

5.3 Chips 74

5.4 Oil Spill 74

5.5 Dust 74

5.6 Wood Dust 75

5.7 Loosen table crank 75

5.8 Broken switch 75

5.9 Missing screw on belt cover 75

5.10 Disorganized cable tie 75

5.11 Example of Fuguai Identified 76

5.12 Bar Chart for Fuguai Types vs Fuguai Frequency 78

5.13 Pie Chart for Fuguai Types 79

5.14 Trend Chart for F-tags Distribution 80

5.15 Spider Chart for Machine Area 81

5.16 Pareto Chart for Machine Area 82

5.17 Column Chart for Fuguai Frequency vs Machine Area 83

5.18 Column Chart for Fuguai Frequency vs Fuguai Category 84

5.19 Pie Chart for Fuguai Category 85

5.20 Trend Chart for Fuguai Category 86

5.21 Poor Condition Table 87

5.22 Good Condition Table 87

5.23 Before Cleaning Process 88

5.24 After Cleaning Process 88

5.25 Poor Condition Base 89

5.26 Good Condition Base 89

5.27 Poor Condition Column 90

5.28 Good Condition Column 90

5.29 Poor Condition Cable Tie 91

5.30 Good Condition Cable Tie 91

xv

5.31 Poor Condition Table Crank 92

5.32 Good Condition Table Crank 92

5.33 Missing Screw on Belt Cover 93

5.34 Loosen Feed Handle 94

5.35 Broken On-Off Switch Cover 95

5.36 Initial Condition (Week 1) 97

5.37 Current Condition (Week 7) 98

xvi

LIST OF TABLES

2.1 Definitions of TPM letters-acronym 14

2.2 Differences between Traditional TPM in Japan and PM in USA 16

2.3 Understanding 5S 21

2.4 16 Major Losses 23

2.5 Training Phase and Skills 25

3.1 A Few Examples of Drilling Machines 38

3.2 General recommendations for Speeds and Feeds in Drilling 40

3.3 General Recommendations for Drill Geometry for High-Speed 41

Twist Drills

3.4 Feature Description 45

3.5 Specifications 48

3.6 Trouble Shooting 49

3.7 General Safety Instructions for Drill Press 51

3.8 Drill Press Operation 55

3.9 Standard of Procedures for Drill Press (16/20 mm) 58

4.1 Gantt Chart of the Project 63

4.2 Descriptions of F-tags Colour Coded 69

4.3 F-Tags Elements 70

5.1 List of Machine Area Derived 72

5.2 List of Fuguai Derived 74

5.3 Data Collected for Fuguai Types 78

5.4 Analysis Based on F-tags Colour 80

5.5 Data Collected for Machine Area 81

5.6 Cumulative Frequency for Machine Area 82

5.7 Analysis of Machine Area Based on Fuguai Category 83

5.8 Tackle and Not Tackle Fuguai 84

5.9 Data Collected for Fuguai Category 85

xvii

5.10 Why-Why Analysis for Mislaid Clamp Vise 87

5.11 Why-Why Analysis for Chips and Wood Dust Scattered 88

5.12 Why-Why Analysis for Oil Spill 89

5.13 Why-Why Analysis for Rusted Column 90

5.14 Why-Why Analysis for Disorganized Cable Tie 91

5.15 Why-Why Analysis for Loosen Table Crank 92

5.16 Why-Why Analysis for Missing Screw on Belt Cover 93

5.17 Why-Why Analysis for Unfastened Feed Handle 94

5.18 Why-Why Analysis for On-Off Broken Switch Box Cover 95

xviii

LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCLATURE

AC - Alternate Current

AM - Autonomous Maintenance

Anon - Anonymous

CBM - Condition-Based Maintenance

CM - Condition Monitoring

FKP - Fakulti Kejuruteraan Pembuatan

F-tag - Fuguai Tag

HP - Horse power

In - Inch

JH - Jishu Hozen

JIPM - Japan Institute of Plant Maintenance

JIT - Just-In-Time

KG - Kilogram

MM - Millimeter

MI - Maintainability Improvement

MP - Maintenance Prevention

NPC - National Productivity Corporation

OEE - Overall Equipment Efficiency

OEL - Overall Equipment Losses

PdM - Predictive Maintenance

PDCA - Plan, Do, Check and Act

PM - Preventive Maintenance

RCM - Reliability-Centered Maintenance

Rev - Revolution

RPM - Rotation Per Minute

SHE - Safety, Health and Environment

xix

SPC - Statistical Process Control

TBM - Time Based Maintenance

TPM - Total Productive Maintenance

TQM - Total Quality Management

USA - United States of America

UTeM - Universiti Teknikal Malaysia Melaka

Vs - Versus

1

CHAPTER 1

INTRODUCTION

1.1 Background

Ford, Eastman Kodak, Dana Corporation., Allen Bradley, Harley Davidson; these are just

a few of the companies that have implemented Total Productive Maintenance (TPM)

successfully. All report an increase in productivity using TPM. Kodak reported that a $5

million investment resulted in a $16 million increase in profits which could be traced and

directly contributed to implementing a TPM program (Roberts, 2007). Patra et. al (2005)

indicated that TPM is a new philosophy of continuous improvement and teamwork that

focuses on delivering these objectives. It is a program for the fundamental improvement

of maintenance functions in an organization, which involves its entire human resources.

TPM was originally developed by the Japanese from the preventive maintenance

strategies used in the United States of America over 30 years ago. TPM is implemented

through eight core activities known as pillars.

Most industrial production systems are subject to deterioration with usage and age. Such

system deterioration may lead to higher production costs and lower product quality and

the increased possibility of breakdown (Hwang and Wang, 2004). It is important for the

machine to be concerned in order to achieve the extended lifetime. Besides that, AM also

suggested to the machines because the technique would assist to eliminate the non-value

added and to keep the machines and work place in a clean and attractive area. The clean

working environment would reduce the number of injuries and accidents. AM attempts to

achieve zero breakdowns, zero accidents, and zero defects situation on the shop floor. If

AM is implemented in a systematic and phased manner in the shop floor, it can bring in

substantial benefits (Nadarajah, 2005).

2

1.2 Problem Statement

Drilling machines are frequently used in Universiti Teknikal Malaysia Melaka (UTeM)

and specifically in the Fitting Laboratory. However, the level of machines maintenance is

not achieving the excellent stage. Moreover, proper maintenance is important to the

machines in order to obtain the extended lifetime. Therefore, it is important for the

project to develop an AM for the drill press (16/20 mm) due to the current total of

machine breakdown in the FKP laboratory.

1.3 Objectives

Specific objectives of the project are:

1. To identify and analyze the abnormalities of the drilling machines and the remedy

towards developing an AM programme for the drill press (16/20 mm).

2. To build up a well-maintained drilling machine.

1.4 Scope of Project

The emphasis of this project is concerned on the development of AM programme for the

drill press (16/20 mm) used in the in Fitting Laboratory in UTeM. The project comprises

of the first three steps of AM which clarified in clause 2.4.3. The project is started from

December 2007 until April 2008. The consequence of this project may not be applicable

to other projects with different types of machines specifically for the drilling machines.

3

1.5 Importance of Project

The importances of the project are:

1. To obtain an extended lifetime for the drilling machine (16/20 mm) used in the

Fitting Laboratory in UTeM for the students.

2. The well-maintained drill press (16/20 mm) would be as a reference for other

types of drilling machines.

3. The machine would be in a clean condition which bring towards friendly working

environment.

1.6 Report Outline

This report writing comprises of six chapters. Chapter 1 describes about the introduction;

which includes the background, problem statement, objectives, scope, and importance of

the project. In the other hand, Chapter 2 stressed on the literature review of maintenance

especially the concept of AM and Chapter 3 highlighted more towards the drilling

machine which is particularly for the drill press (16/20 mm). Chapter 4 is the research

methodology. This chapter is discussed the research methodology that were used to

gather the data required to support the development and analysis of the study. This

chapter also comprises of the process planning, flowchart, data gathering method and

analytical technique of Fuguai. In Chapter 5, the results and discussions will go through

the development of maintenance programme for drill press (16/20 mm). Finally, Chapter

6 will provide the conclusions and the recommendations of the whole project.

4

CHAPTER 2

MAINTENANCE

Chapter two describes all about maintenance. The discussion starts with the introduction

to maintenance, which is including the definition of maintenance, the importance of

maintenance and also the various types of maintenance. Moreover, the TPM and the AM

is discussed.

2.1 Maintenance

It is difficult to imagine a time when equipment was not maintained. Remarkably

enough, maintenance and productivity have not always been the Holy Grail of industry

that they become in today’s most successful companies (Borris, 2006). Maintenance, as a

system, plays a key role in achieving organizational goals and objectives. It contributes to

reducing coast, minimizing equipment downtime; improving quality, increasing

productivity and providing reliable equipment that are safe and well-configured to

achieve timely delivery of orders to customers.

There are various definitions of maintenance. Almost everyone in this world would

define maintenance in a different way because everybody has their own perceptions and

opinions. What is maintenance and why is it performed? Past and current maintenance

practices in both the private and government sectors would imply that maintenance is the

actions associated with equipment repair after it is broken. This would imply that

maintenance should be actions taken to prevent a device or component from failing or to

repair normal equipment (Anon, 2007g).

5

According to Levitt (1997), maintenance is a war. The enemies are break down,

deterioration, and the consequences of all types of unplanned events. However, Luxhoj

et. al, (1997) described maintenance as a support function within the industrial enterprise.

Traditionally, maintenance has been seen as an essential activity to keep the production

process going. It is not uncommon to find proponents of planned, preventive, predictive,

condition-based maintenance strategies arguing the merits of their chosen method. Since

maintenance is seen as a cost, the argument often veers around to how the preferred

method helps contain costs. Maintenance may be defined most effectively by what it

does, namely, the preservation or restoration of the desired function of a given process, at

the lowest total cost (Narayan, 1998).

Campbell et. al. (1999) emphasized that maintenance is defined as the combination of

activities by which equipment or a system is kept in, or stored to, a state in which it can

perform its designated functions. On the other hand, Kelly (2000) indicates that the

maintenance is used to sustain the integrity of physical assets by repairing, modifying or

replacing them as necessary.

Maintenance means maintaining and improving the integrity of the production and

quality systems through the machines, processes, equipment and people who add value to

our products and services (McCarthy and Willmott, 2001). Nevertheless, Besterfield et.

al. (2003) declares that the maintenance keeping equipment and plant in as good as or

better than the original condition at all times. Maintenance is a unique business process

(Wireman, 2004). Maintenance requires an approach that is different from other business

processes if it is to be successfully managed. Yet, Jardine and Tsang (2006) classified

maintenance as a medium which is used to fix broken items.

2.2 Importance of Maintenance

Most industrial production systems are subject to deterioration with usage and age. Such

system deterioration may lead to higher production costs and lower product quality and

the increased possibility of breakdown (Hwang and Wang, 2004).